Roofing Shingles with Integrated Handle Cutouts

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Solution Overview

Problem

Roofing shingles and solar shingles lack efficient features for carrying and transportation, making them difficult to handle and move during installation and maintenance.

Innovation Solution

Incorporating a handle with a cutout and gripping portion into the roofing shingle design, allowing for easier grasping and alignment with other shingles for simultaneous handling and transportation, which can be ultrasonically welded, heat welded, or thermally bonded to the head lap.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If roofing shingles are designed without handles, then the shingle structure remains simple and manufacturing is easier, but carrying and transportation become difficult and inefficient

Engineering Contradiction:

Improvecarrying and transportationVSAvoidshingle structure

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The shingle is segmented by introducing a cutout feature that divides the head lap into distinct regions, creating a handle portion that can be grasped separately from the main shingle body. This segmentation enables independent handling of the shingle during transportation without affecting the overall structural integrity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

An external object (such as a tool or carrier) is introduced as an intermediary that fits through the cutout to provide a gripping mechanism. This intermediary element facilitates carrying and transportation by bridging the user's hand and the shingle surface, eliminating the need for direct grasping of the shingle material itself.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If handles are added to roofing shingles, then gripping and handling become easier, but manufacturing complexity and production time increase

Engineering Contradiction:

Improvegripping and handlingVSAvoidproduction process

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

The cutout is pre-formed in the head lap during the shingle manufacturing process, creating the handle structure before the shingle is completed. This preliminary action ensures that the handle feature is already in place when the shingle is installed, eliminating the need for post-manufacturing modifications or additional assembly steps.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The handle structure is designed to be self-forming through the cutout geometry itself, without requiring separate handle components or additional attachment mechanisms. The cutout portion of the head lap serves dual purposes: maintaining structural integrity while providing the gripping feature, thus eliminating the need for separate handle manufacturing and attachment processes.

Inventive Principle:

Principle #25Self-service

3Productivity

If multiple shingles are carried simultaneously, then transportation efficiency improves, but alignment and handling of multiple shingles becomes more difficult

Engineering Contradiction:

Improvetransportation efficiencyVSAvoidalignment and handling

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The cutout handle design is made universal across all shingles, allowing the same external object or carrying mechanism to interact with multiple shingles in the same way. This universality enables consistent alignment and handling of multiple shingles during transportation, as each shingle presents the same gripping interface to the carrier.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The cutout creates a new dimensional interface (a through-opening) that allows external objects to engage with the shingle from the outside, rather than requiring surface-level gripping. This dimensional change enables multiple shingles to be stacked or grouped together with a single carrying mechanism passing through all cutouts, facilitating simultaneous handling of multiple units.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Facilitates efficient carrying and transportation of roofing shingles by providing a secure grip and alignment mechanism, enhancing user convenience and reducing handling difficulties.

Implementation Method 1

The at least one handle may be ultrasonically welded, heat welded, or thermally bonded to the head lap

Methodology Applied

Scientific EffectUltrasonic welding: Ultrasonic Vibration

Implementation Method 2

The at least one handle may be ultrasonically welded, heat welded, or thermally bonded to the head lap

Methodology Applied

Scientific EffectHeat welding: Welding

Implementation Method 3

The at least one handle may be ultrasonically welded, heat welded, or thermally bonded to the head lap

Methodology Applied

Scientific EffectThermal bonding: Heating

Data Source

PatentUS11661745B2Roofing shingles with handles

Publication Date: 2023.05.30 GAF ENERGY LLC

AI summary

A roofing shingle includes a head lap and at least one solar cell. The head lap includes at least one handle located between a first end and a second end of the shingle and proximate to a first edge thereof. The at least one handle includes at least one cutout and a gripping portion. The at least one cutout is sized and shaped to receive an external object to facilitate transporting the shingle by a user.